KTM60SX65SX982002

60SX/65SXREPAIRMANUALENGINEKTMSPORTMOTORCYCLEAG5230MattighofenAustria(s)Replacebypage(s)Insertpage(s)afterpage2-3to2-62-3dto2-6d3-43-4d4-1to4-84-1dto4-9d5-2to5-75-2dto5-7d6-1to6-96-1dto6-10d7-17-1d7-47-4d8-1to8-138-1dto8-12d9-19-1d9-69-6dto9-8dIMPORTANTINFORMATION/UPDATINGINSTRUCTIONSTobeabletocontinueusingtheexistingloose-leafrepairinstructions,simplyprintthefollowingpagesandinsertthemintheexistingrepairinstructions:7,9,17-20,25,26,29-38,41-46,51-61,63,67-81,83,89-91KTMREPAIRMANUALINLOOSE-LEAFFORMSTORINGTHEREPAIRMANUALINTHEBINDER–Puttheindexintothebinder.–Putthefrontpageoftherepairmanual(210x297mm)intothetransparentpocketprovidedforthispurposeontheoutsideofthebinder.–Putthespinelabel(170x45mm)intothetransparentpocketprovidedforthispurposeonthespineofthebinder.–Putthesummarylistofcontents(150x297mm)intothetransparentpocketprovidedforthispurposeontheinsideofthebinderorinsertthispageonthebeginningofthemanual.–Theninserttheindividualchaptersofthemanualbetweenthesheetsoftheindexaccordingtothepagenumberprintedintherightbottomcornerofeachpage.Example:pageno.3-53=chapter35=page5Allpageswithapagenumberthatbeginswiththedigit3,forexample,mustbeputundertheindexheading„Chapter3“.–Indexsheetsthathavenotbeenmarkedwithacertainchapterareforyourpersonalconvenience.Therespectiveheadingscanbeenteredinthelistofcontents.EXPLANATION-UPDATINGEdition6/2002Thisrepairmanualcontainsthefollowingsupplements:3.205.46-ERepairManual60SX/65SXBasicversionModelyear19983/19983.205.75-EUpdatingofRep.Manual3.205.46-EModelyear19995/19993.210.05-EUpdatingofRep.Manual3.205.46-EModelyear2000/20012/20012000:fromenginenumberB60000001fromenginenumberB650000012001:fromenginenumberB651000013.210.36-EUpdatingofRep.Manual3.205.46-EModelyear200211/2001fromenginenumberB652000013.210.66-EUpdatingofRep.Manual3.205.46-EModelyear20036/2002fromenginenumberB65300001Modification/Updating:Specialtools,technicaldetailsmodel2003,ignition,measurementswithPVA,technicalspecification,periodicmaintenancescheduleINTRODUCTIONThisrepairmanualoffersextensivrepair-instructionsandisanup-to-dateversionthatdescribesthelatestmodelsoftheseries.However,therighttomodificationsintheinterestoftechnicalimprovementisreservedwithoutupdatingthecurrentissueofthismanual.Adescriptionofgeneralworkingmodescommoninworkshopshasnotbeenincluded.Safetyrulescommonintheworkshophavealsonotbeenlisted.Wetakeitforgrantedthattherepairsaremadebyqualifiedprofesionallytrainedmechanics.Readthroughtherepairmanualbeforebeginningwiththerepairwork.
WARNING
STRICTCOMPLIANCEWITHTHESEINSTRUCTIONSISESSENTIALTOAVOIDDANGERTOLIFEANDLIMB.!CAUTION!NON-COMPLIANCEWITHTHESEINSTRUCTIONSCANLEADTODAMAGEOFMOTORCYCLECOMPONENTSORRENDERMOTORCYCLESUNFITFORTRAFFIC!„NOTE”POINTSOUTUSEFULTIPS.UseonlyORIGINALKTMSPAREPARTSwhenreplacingparts.TheKTMhighperformanceengineisonlyabletomeetuserexpectationsifthemaintenanceworkisperformedregularlyandprofessionally.KTMAustria’scertificateofachievementforitsqualitysystemISO9001isthebeginningofanongoingtotalreengineeredqualityplanforabrightertomorrow.KTMSportmotorcycleAG5230Mattighofen,AustriaAlldesignandassemblymodificationrightsreserved.CbyKTMSPORTMOTORCYCLEAG,AUSTRIAAllrightsreservedREPLYFAXFORREPAIRMANUALSWehavemadeeveryefforttomakeourrepairmanualsasaccurateaspossiblebutitisalwayspossibleforamistakeortwotocreepin.Tokeepimprovingthequalityofourrepairmanuals,werequestmechanicsandshopforementoassistusasfollows:Ifyoufindanyerrorsorinaccuraciesinoneofourrepairmanual–whetherthesearetechnicalerrors,incorrectorunclearrepairprocedures,toolproblems,missingtechnicaldataortorques,inaccurateorincorrecttranslationsorwording,etc.–pleaseentertheerror(s)inthetablebelowandfaxthecompletedformtousat0043/7742/6000/5349.NOTEtotable:–Enterthecompleteitemno.fortherepairmanualincolumn1(e.g.:3.210.66-E).Youwillfindthenumberonthecoverpageorintheleftmarginoneachrightpageofthemanual.–Enterthecorrespondingpagenumberintherepairmanual(e.g.:5-7c)incolumn2.–Enterthecurrenttext(inaccurateorincomplete)incolumn3byquotingordescribingtherespectivepassageofthetext.Ifyourtextdeviatesfromthetextcontainedintherepairmanual,pleasewriteyourtextinGermanorEnglishifpossible.–Enterthecorrecttextincolumn4.Yourcorrectionswillbereviewedandincorporatedinthenextissueofourrepairmanual.Itemno.ofrepairmanualPageCurrenttextCorrecttextAdditionalsuggestions,requestsorcommentsonourRepairManuals(inGermanorEnglish):Namemechanic/shopforemanCompany/workshopGENERALINFORMATIONCARBURETORADJUSTMENT.................................2-2BLEEDINGOFTHEHYDRAULICCLUTCH.........................2-3SPECIALTOOLS............................................2-4CLEANING................................................2-6STORAGE.................................................2-6INDEX2RepairmanualKTM60SX+65SXArt.-No.321066-E2